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МАСЛЯНЫЙ НАСОС СНЯТИЕ

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Note:

  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

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  1. Click here

    REMOVE ENGINE ASSEMBLY

    (Click here)

  2. Click here

    DISCONNECT ENGINE WIRE


    1. Disconnect the connectors and detach the clamps securing the engine wire to the engine, remove the bracket bolts and disconnect the engine wire from the engine.

  3. Click here

    REMOVE GENERATOR ASSEMBLY


    1. A01ISLO

      Remove the 3 bolts and generator.

  4. Click here

    REMOVE VACUUM PUMP ASSEMBLY


    1. A01IOLN

      Disconnect the vacuum hose.

    2. Remove the 3 bolts and vacuum pump.

    3. Remove the 2 O-rings from the vacuum pump.

  5. Click here

    REMOVE IDLER PULLEY COVER PLATE


    1. A01INKKE01

      Using a screwdriver, remove the idler pulley cover plate.

      Table 1. Text in Illustration
      *1 Tape
      Tip:

      Tape the screwdriver tip before use.

  6. Click here

    REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A01INUC

      Remove the bolt and No. 1 idler pulley.

  7. Click here

    REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A01IQMTE01

      Remove the bolt, No. 2 idler pulley cover plate and No. 2 idler pulley.

      Table 2. Text in Illustration
      *1 No. 2 Idler Pulley Cover Plate
      *2 No. 2 Idler Pulley
  8. Click here

    REMOVE NO. 4 WATER BY-PASS PIPE


    1. A01IU1R

      Remove the bolt and No. 4 water by-pass pipe from the water inlet housing.

    2. Remove the O-ring from the No. 4 water by-pass pipe.

  9. Click here

    REMOVE ENGINE MOUNTING BRACKET


    1. A01IQJU

      Remove the 4 bolts, 2 nuts and engine mounting bracket.

  10. Click here

    REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01IU2Z

      Remove the 3 bolts and V-ribbed belt tensioner.

      Note:

      As the heads of the bolts are not as thick as those of typical bolts, be careful not to damage them during removal.

  11. Click here

    REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01IU98E01

      Disconnect the No. 6 and No. 7 water by-pass hoses.

      Table 3. Text in Illustration
      *1 No. 6 Water By-pass Hose
      *2 No. 7 Water By-pass Hose
    2. A01IS0N

      Remove the 2 bolts, 2 nuts, diesel throttle body and gasket.

  12. Click here

    REMOVE NO. 7 WATER BY-PASS HOSE

  13. Click here

    DISCONNECT NO. 8 WATER BY-PASS HOSE

  14. Click here

    REMOVE EGR VALVE BRACKET


    1. A01IPI2

      Remove the 3 bolts and 2 brackets.

  15. Click here

    REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    1. A01IOQA

      Disconnect the electric EGR control valve connector.

    2. A01IPRKE01

      Remove the 3 bolts, 2 nuts, No. 2 EGR pipe and 2 gaskets.

      Table 4. Text in Illustration
      *1 Nut
  16. Click here

    REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01IQP8

      Remove the electric EGR control valve and gasket.

  17. Click here

    REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A01IN7K

      Remove the 2 bolts and engine oil level dipstick guide.

    3. Remove the O-ring from the engine oil level dipstick guide.

  18. Click here

    REMOVE FUEL INLET PIPE SUB-ASSEMBLY

    Note:

    After removing the fuel inlet pipe, cover the common rail and supply pump with electrical tape to prevent dirt from entering them.


    1. A01ITN1

      Remove the nut and 2 clamps.

    2. Using a 14 mm union nut wrench, remove the fuel inlet pipe.

  19. Click here

    REMOVE INJECTION PIPE SUB-ASSEMBLY

    Note:

    After removing the injection pipe, to prevent dirt or foreign objects from entering the pipe inlet, cover the common rail with electrical tape. Also protect the injector inlets with electrical tape or plastic bags.


    1. A01IO2G

      Remove the 2 bolts and 4 injection pipe clamps.

    2. Using a 14 mm union nut wrench, loosen the 4 nuts at the common rail end of the injection pipes.

    3. Using a 14 mm union nut wrench, loosen the 4 nuts at the injector end of the injection pipes.

    4. Remove the 4 injection pipes.

  20. Click here

    REMOVE NO. 4 FUEL HOSE

  21. Click here

    REMOVE COMMON RAIL ASSEMBLY


    1. A01ITVG

      Remove the 2 bolts and common rail.

  22. Click here

    REMOVE INTAKE MANIFOLD INSULATOR


    1. A01IQK4

      Remove the intake manifold insulator from the intake manifold.

  23. Click here

    REMOVE DIESEL TURBO PRESSURE SENSOR


    1. A01IQ0K

      Disconnect the vacuum hose.

    2. Remove the bolt and sensor.

  24. Click here

    REMOVE NO. 1 GAS FILTER


    1. A01IQMA

      Disconnect the vacuum hose.

    2. Remove the No. 1 gas filter from the gas filter bracket.

  25. Click here

    REMOVE GAS FILTER BRACKET


    1. A01ITRH

      Remove the 2 bolts and gas filter bracket.

  26. Click here

    REMOVE ENGINE COVER BRACKET


    1. A01INXS

      Remove the bolt and engine cover bracket.

  27. Click here

    REMOVE NO. 2 INTAKE MANIFOLD


    1. A01IPPN

      Remove the bolt, 2 nuts, No. 2 intake manifold and gasket.

  28. Click here

    REMOVE INTAKE MANIFOLD


    1. A01IOHHE01

      Remove the 7 bolts, 2 nuts, intake manifold and gasket.

      Table 5. Text in Illustration
      *1 Nut

    2. Remove the gasket from the cylinder head.

  29. Click here

    REMOVE WATER BY-PASS HOSE

  30. Click here

    REMOVE OIL COOLER ASSEMBLY


    1. A01IRXA

      Remove the 5 bolts and oil cooler.

    2. Remove the 3 O-rings from the oil cooler bracket.

  31. Click here

    REMOVE NO. 6 WATER BY-PASS HOSE

  32. Click here

    REMOVE NO. 8 WATER BY-PASS HOSE

  33. Click here

    REMOVE NO. 3 WATER BY-PASS PIPE


    1. A01IT3O

      Remove the 2 bolts and No. 3 water by-pass pipe.

    2. Remove the O-ring from the No. 3 water by-pass pipe.

  34. Click here

    REMOVE NO. 1 TURBO OIL PIPE


    1. A01INN5

      Remove the 2 union bolts, 2 gaskets and No. 1 turbo oil pipe.

  35. Click here

    REMOVE NO. 1 OIL COOLER BRACKET


    1. A01ISIE

      Remove the 6 bolts, nut and No. 1 oil cooler bracket.

      Table 6. Text in Illustration
      A01ISER Nut

    2. Remove the 3 O-rings from the No. 1 oil cooler bracket.

  36. Click here

    REMOVE NO. 1 CYLINDER BLOCK INSULATOR


    1. A01INKR

      Remove the No. 1 cylinder block insulator from the cylinder block.

  37. Click here

    REMOVE NO. 2 WATER BY-PASS PIPE


    1. A01IP5C

      Remove the 2 bolts and No. 2 water by-pass pipe from the water inlet housing.

    2. Remove the O-ring from the No. 2 water by-pass pipe.

  38. Click here

    REMOVE NO. 4 WATER BY-PASS HOSE

  39. Click here

    REMOVE WATER INLET HOUSING


    1. A01IUI2

      Remove the 3 nuts and water inlet housing.

    2. Remove the gasket from the water inlet housing.

  40. Click here

    REMOVE NO. 2 FUEL PIPE (for CCo)


    1. A01IN5Z

      Remove the check valve and gasket.

      Table 7. Text in Illustration
      A01ISER Check Valve

    2. Remove the union bolt, gasket and fuel pipe.

  41. Click here

    REMOVE FUEL HOSE PROTECTOR (for DPF)


    1. A01INWG

      Remove the bolt and fuel hose protector.

  42. Click here

    REMOVE FUEL TUBE SUB-ASSEMBLY (for DPF)


    1. A01IT57

      Disconnect the exhaust fuel addition injector connector.

    2. A01IQ6B

      Turn the retainer as shown in the illustration.

    3. A01IUL8

      Disconnect the fuel tube from the exhaust fuel addition injector.

    4. A01INMW

      Remove the check valve and gasket.

      Table 8. Text in Illustration
      A01ISER Check Valve

    5. Remove the union bolt, gasket and fuel tube.

  43. Click here

    REMOVE NO. 3 FUEL HOSE

  44. Click here

    REMOVE NO. 2 NOZZLE LEAKAGE PIPE


    1. A01IO69

      Remove the check valve and gasket.

      Table 9. Text in Illustration
      A01ISER Check Valve

    2. Remove the bolt and No. 2 nozzle leakage pipe.

  45. Click here

    REMOVE NO. 1 NOZZLE LEAKAGE PIPE


    1. A01ISVS

      Remove the 4 union bolts and 4 gaskets.

    2. Remove the bolt and No. 1 nozzle leakage pipe.

  46. Click here

    REMOVE NO. 1 NOZZLE HOLDER CLAMP


    1. A01IOF9

      Remove the 4 bolts, 4 washers and 4 nozzle holder clamps.

  47. Click here

    REMOVE INJECTOR ASSEMBLY


    1. Remove the 4 injectors and 4 injection nozzle seats from the cylinder head.

    2. Remove the O-ring from each injector.

      Note:

      When removing the injector assembly, store the injectors in the correct order so that they can be returned to their original locations when reassembling.

  48. Click here

    REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY


    1. A01ITBIE01

      Pinch the clip as shown in the illustration, and pull out the VSV connector.

      Table 10. Text in Illustration
      *a Pinch
    2. A01IQO4

      Disconnect the 2 vacuum hoses.

    3. Using a 4 mm hexagon socket wrench, remove the 2 bolts and VSV.

  49. Click here

    REMOVE VACUUM REGULATING VALVE ASSEMBLY


    1. Disconnect the vacuum regulating valve connector.

    2. A01IQN9

      Disconnect the 2 vacuum hoses.

    3. Remove the 2 bolts and vacuum regulating valve.

  50. Click here

    REMOVE VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01IO8X

      Detach the 10 clamps and remove the 2 vacuum transmitting hoses.

  51. Click here

    REMOVE PCV HOSE

  52. Click here

    REMOVE OIL FILLER CAP SUB-ASSEMBLY

  53. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01IN9G

      Remove the 4 nozzle holder clamp seats, 14 bolts, nut and cylinder head cover.

      Table 11. Text in Illustration
      A01ISM9 Bolt
      A01ISER Nozzle Holder Clamp Seat
      A01IQPE Nut
    2. A01IN7I

      Remove the cylinder head cover gasket from the cylinder head cover.

  54. Click here

    REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01IU0W

      Remove the 18 bolts and 2 nuts.

      Table 12. Text in Illustration
      A01ISER Nut
    2. A01IPIFE06

      Insert the blade of an oil pan seal cutter between the oil pan and cylinder block, cut through the applied sealer and remove the oil pan.

      Note:

      • Do not use the oil pan seal cutter for the area between the oil pan and timing chain cover.

      • Be careful not to damage the contact surfaces of the oil pan.

  55. Click here

    REMOVE OIL FILTER ELEMENT


    1. A01INHEE08

      Connect a hose with an inside diameter of 15 mm (0.591 in.) to the oil filter drain pipe.

      Table 13. Text in Illustration
      *1 Oil filter drain pipe
      *2 Hose
    2. A01IPQG

      Remove the oil filter drain plug.

    3. Remove the O-ring from the oil filter drain plug and install it to an oil filter drain pipe.

    4. A01INEKE01

      Install the oil filter drain pipe to the oil filter cap and drain the engine oil.

      Table 14. Text in Illustration
      *1 Oil Filter Cap
      *2 O-Ring
      *3 Oil Filter Drain Pipe

    5. Remove the oil filter drain pipe.

    6. Apply a light coat of engine oil to a new O-ring and install it to the oil filter drain plug.

    7. Install the oil filter drain plug to the oil filter cap.

      13 N*m 127 kgf*cm 9 ft.*lbf
    8. A01ITUTE01

      Using SST, remove the oil filter cap.

      09228-06501
    9. A01ITLEE01

      Remove the oil filter element and O-ring from the oil filter cap.

      Table 15. Text in Illustration
      *1 Oil Filter Element
      *2 O-Ring
      Note:

      Be sure to remove the cap O-ring by hand without using any tools to prevent damage to the cap O-ring groove.

  56. Click here

    REMOVE OIL FILTER BRACKET


    1. A01IU3I

      Remove the 4 bolts and oil filter bracket.

    2. A01IOF2

      Remove the gasket from the oil filter bracket.

  57. Click here

    REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01IPZE

      Remove the 3 bolts and oil strainer.

    2. Remove the O-ring from the oil strainer.

  58. Click here

    REMOVE CAMSHAFT POSITION SENSOR


    1. A01IN28

      Remove the bolt and sensor.

  59. Click here

    DISCONNECT CRANKSHAFT POSITION SENSOR WIRE HARNESS


    1. A01IP27

      Using a clip remover, remove the clip.

    2. Remove the bolt and disconnect the sensor wire harness.

  60. Click here

    REMOVE WATER PUMP ASSEMBLY


    1. A01IS2Y

      Remove the 7 bolts, water pump assembly and gasket.

  61. Click here

    REMOVE CRANKSHAFT PULLEY


    1. Set the No. 1 piston to TDC/compression.


      1. A01ITG4E01

        Turn the crankshaft pulley clockwise to align the timing mark on the pulley with the timing pointer of the timing chain cover.

        Table 16. Text in Illustration
        *1 Timing Pointer
        *2 Timing Mark
    2. A01IUCUE01

      Make sure that the timing mark of the camshaft timing sprocket is at the top.

      Table 17. Text in Illustration
      *1 Matchmark
      *2 Timing Mark
      Tip:

      If the timing mark is not at the top, turn the crankshaft pulley 1 revolution so that the timing mark is at the top (set the No. 1 piston to TDC/compression).

    3. Put a matchmark on the timing chain plate that is aligned with the timing mark of the camshaft timing sprocket.

      Tip:

      The timing chain has 2 yellow-colored plates. If either of them is aligned with the timing mark of the camshaft timing sprocket, this step can be omitted.

    4. A01IUJCE01

      Turn the crankshaft by approximately 90° in the direction of engine revolution from the point where the No. 1 piston is set to TDC/compression so that the lifted valve and piston do not contact each other when removing the camshaft.

    5. A01IPB5E01

      Using SST, loosen the pulley bolt.

      09213-58014 91551-80840
      09330-00021
    6. A01IR03E01

      Using SST, remove the pulley bolt and crankshaft pulley.

      09950-50013 09951-05010 09952-05010 09953-05020 09954-05021
  62. Click here

    REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01IQAE

      Remove the 13 bolts and seal washer.

      Table 18. Text in Illustration
      A01ISER Bolt and Seal Washer
    2. A01ITQ6

      Remove the timing chain cover by prying between the timing chain cover and cylinder head, camshaft housing, cylinder block and stiffening crankcase with a screwdriver as shown in the illustration.

      Note:

      Be careful not to damage the contact surfaces of the cylinder head, camshaft housing, cylinder block, stiffening crankcase and chain cover.

      Tip:

      Tape the screwdriver tip before use.

    3. A01ISRGE01

      Remove the gasket and O-ring from the timing chain cover.

      Table 19. Text in Illustration
      *1 Gasket
      *2 O-Ring
  63. Click here

    REMOVE STRAIGHT SCREW PLUG


    1. A01IRH1

      Using a 10 mm socket hexagon wrench, remove the straight screw plug and gasket.

  64. Click here

    REMOVE FRONT CRANKSHAFT OIL SEAL


    1. A01ISUE

      Place the timing chain cover on wooden blocks.

    2. Using a screwdriver, pry out the oil seal.

      Note:

      Do not damage the surface of the oil seal press fit hole.

      Tip:

      Tape the screwdriver tip before use.

  65. Click here

    REPLACE STUD BOLT

    Tip:

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. A01ISXOE01

      Using an E6 "TORX" wrench, replace the 3 stud bolts.

      3.0 N*m 31 kgf*cm 27 in.*lbf